Automated Palletising in Bedford: Improving Throughput, Safety, and Consistency
Manufacturers and logistics teams are under constant pressure to increase output, reduce costs, and improve safety without compromising quality. That is exactly where Automated Palletising in Bedford can deliver real, measurable value. By replacing repetitive manual stacking with a well-designed robotic cell, businesses can achieve consistent pallet patterns, lower product damage, and maintain dependable production flow across shifts. At Premier Automation, we design and build new robot systems, integrate used robots, and upgrade or relocate existing automation to match your process requirements and payback criteria.
Founded in 2000, Premier Automation has developed into one of the UK’s leading suppliers of robot-based Automation and Control Systems. Operating from our large facility in Bedford, we support customers locally, nationally, and internationally with robust solutions, honest advice, and engineering expertise that focuses on long-term reliability.
What Automated Palletising in Bedford actually involves
Robotic palletising is the automated stacking of cartons, cases, trays, or other products onto pallets in repeatable patterns, usually at the end of a production line. Automated Palletising in Bedford typically combines a robot arm, infeed conveyor, guarding and safety systems, and a control platform that coordinates the full cell. The result is a pallet load that is stable, uniform, and built to maximise space efficiency during storage and transport.
A well-integrated palletising solution also considers what happens before and after the pallet build. That can include product orientation on the infeed, pallet supply and pallet handling, and integration with downstream equipment such as stretch wrappers or pallet conveyors. The most effective projects begin with a clear understanding of your product range, throughput targets, available floor space, and how the palletised loads will be used in your wider operation.
Premier Automation applies design and process expertise to ensure each solution is robust and reliable. Whether you need a simple single-line system or a more sophisticated end-of-line cell with multiple infeeds and automated pallet supply, we tailor the approach to your commercial and technical criteria.
Automated Palletising in Bedford for higher throughput and reliable uptime
One of the biggest drivers for automation is output. Manual palletising often becomes a bottleneck, particularly when production speed increases, shift patterns change, or product weight and repetition create fatigue. Automated Palletising in Bedford supports consistent cycle times and predictable performance, helping you maintain flow even during peak periods.
Robotic cells can also reduce the downtime associated with changeovers, especially when supported by off-line programming and simulation. Premier Automation uses tools such as RobotStudio and Siemens PLC Sim to create and edit programmes off-line, which minimises disruption during commissioning and future updates.
Because we work with a wide range of robot models from leading manufacturers, we can recommend an approach that suits your product and throughput rather than forcing a one-size-fits-all design. Our engineers have extensive experience across installations ranging from single-cell systems to multi-technology automation lines.
Automated Palletising in Bedford to reduce manual handling risks
Palletising can be physically demanding. Repetitive lifting, twisting, and stacking increases the risk of strain injuries and fatigue, particularly in environments where operators are also managing other tasks. Automated Palletising in Bedford helps by transferring the heavy, repetitive element of the job to a robot system designed to operate safely and consistently.
In practical terms, automation can:
Reduce repetitive strain and manual handling risk
Keep pallet patterns consistent for safer transport
Lower the chance of product damage during stacking
Free operators for higher-value tasks in production
Safety is also about control and compliance. Premier Automation designs control systems in the latest Eplan platform and delivers full schematics, parts lists, panel layouts, cable schedules, EN13849 safety reports, and controls risk assessments. Our panels are built in-house, fully tested prior to despatch, and compliant with the relevant British and European standards and directives.
Choosing between industrial robots and cobots
Not every palletising application needs the same type of robot. Traditional industrial palletising robots can achieve high speeds and handle heavier payloads, while collaborative robots (cobots) can be a strong option for lower-throughput lines, tighter spaces, or high-mix operations where flexibility is essential.
When considering Automated Palletising in Bedford, the decision often depends on:
Product weight and dimensions
Line speed and throughput targets
Available footprint and cell layout
Changeover frequency and SKU variation
Safety requirements and operator interaction
Premier Automation has designed palletising cells based around robots such as the ABB IRB 460, and also cobot palletising solutions using platforms such as the ABB GoFa. For example, a basic palletising cell can be configured with a single infeed conveyor and one pallet position, while twin palletising cells can support two infeeds and two pallet positions. Cobot palletising cells can be configured for multiple pallet locations, and conveyor palletising options are available where pallet movement is automated.
We also design and manufacture grippers and tooling to suit many different products, which is often the key to achieving reliable pick performance and stable pallet loads.
Automated Palletising in Bedford with integration, controls, and commissioning
A palletising robot is only as good as the system around it. That is why Premier Automation delivers end-to-end integration, covering design, build, installation, and commissioning. Automated Palletising in Bedford projects often include conveyors, guarding, pallet supply, sensors, safety interlocks, and a user interface that makes the cell intuitive to operate.
Premier Automation is proud to be a Siemens Solution Partner, and we treat control systems as the heart of the automation. Our electricians wire up systems on site, test power supplies and I/O, and our software engineers install and commission the control software, including operator training where required.
We also offer upgrades and relocation services. If you already have a robot cell that needs higher throughput, improved reliability, or adaptation for new products, we can assess and re-engineer your system. If you are reorganising production or moving sites, we can relocate systems within the UK or internationally, helping reduce risk and downtime.
What to expect from a Premier Automation palletising project
Every facility is different, so the best place to start is a system assessment and site survey. We will review your current process, discuss your products and throughput goals, and identify the best technical route to achieving your payback criteria. From there, we can propose a solution that suits your space, your line layout, and your operational needs.
A typical project may include:
Concept design and cell layout
Robot selection, tooling, and gripper design
Control system design and panel manufacture
Build, factory testing, and documentation
On-site installation, commissioning, and training
After sales support and future optimisation
If you are exploring a new cell, modifying an existing robot, or relocating an automation line, Premier Automation will provide honest, unbiased advice to guide you to the most appropriate solution.
